WORKSHOP MANUAL

TECHNICAL NETWORK LEADERSHIP

WORKSHOP MANUAL
-

125 CC/150 CC 4-STROKE ENGINE

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 Workshop manual
Technical network leadership
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 TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS........................................................................................................ 1

CHARACTERISTICS............................................................................................................ 3

Capacities............................................................................................................................ 3

SPECIAL IMPORTANT POINTS.......................................................................................... 4

Oil and fuel .......................................................................................................................... 4

TIGHTENING TORQUE........................................................................................................ 5

SPECIAL TOOLS ................................................................................................................. 6

DISASSEMBLY .................................................................................................................... 9

Putting the engine on the stand........................................................................................... 9

Removal of the primary transmission cover......................................................................... 9

Removal of the drive pulley................................................................................................ 10

Removal of the driven pulley.............................................................................................. 10

Removal of the rocker cover. ............................................................................................. 11

Removal of the chain tensioner. ........................................................................................ 11

Removal of the RH cover / ignition coil and sensor. .......................................................... 12

Removal of the rotor. ......................................................................................................... 13

Removal of the cylinder head. ........................................................................................... 14

Removal of the temperature sensor. ................................................................................. 16

Removal of the thermostat. ............................................................................................... 16

Removal of the camshaft and/or rockers. .......................................................................... 16

Removal of the valves or valve stem seals........................................................................ 17

Removal of the cylinder. .................................................................................................... 19

Removal of the piston........................................................................................................ 19

Removal of the oil pump. ................................................................................................... 20

Removal of the RH crankcase half. ................................................................................... 22

Removal of the oil discharge valve. ................................................................................... 23

Removal of the water pump............................................................................................... 23

Removal of the crankshaft. ................................................................................................ 24

1
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 TABLE OF CONTENTS

Checking the crankshaft and conrod assembly. ................................................................ 25

Removal of the secondary transmission cover. ................................................................. 26

Removal of the secondary transmission............................................................................ 26

REFITTING SPECIFIC COMPONENTS............................................................................. 28

Installing the crankshaft LH bearing. ................................................................................. 28

Installing the water pump inside the RH crankcase........................................................... 28

Assembly of the engine casings. ....................................................................................... 30

Installing the piston rings on the piston. ............................................................................ 32

Fitting the piston. ............................................................................................................... 32

Fitting the cylinder ............................................................................................................. 33

Fitting the cylinder head. ................................................................................................... 33

Setting the timing............................................................................................................... 35

Installing the valve clearance............................................................................................. 37

Checking the valve clearance............................................................................................ 37

Refitting the rocker cover. .................................................................................................. 38

MISCELLANEOUS OPERATIONS .................................................................................... 39

Removal of the oil filter. ..................................................................................................... 39

Removal of the water inlet pipe. ........................................................................................ 39

Fitting the drive pulley assembly........................................................................................ 40

Changing the drive pulley bearings. .................................................................................. 40

Removal of the clutch lining assembly. .............................................................................. 41

Refitting the clutch lining assembly.................................................................................... 42

2
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 CHARACTERISTICS

CHARACTERISTICS

125 cc 150 cc 125 cc EFI 150 cc EFI

Marking FD1 FD2 FD4/FD5 FD4
Type 4-stroke single-cylinder
Cooling Liquid
Bore x stroke 57 x 48,9 mm 57 x 58,9 mm 57 x 48,9 mm 57 x 58,9 mm
Cubic capacity 124,8 cc 150 cc 124,8 cc 150 cc
Max. power output 9 kW at 8750 rpm 10 kW at 8450 rpm 9 kW at 8750 rpm 10 kW at 8450 rpm
Max. torque rating 7250 rpm 6500 rpm 7250 rpm 6500 rpm
Lubrication Trochoidal pump
Transmission By 2 variable pulleys and V-type belt
Clutch Centrifugal automatic
Exhaust Non-catalytic
Starter motor Mitsuba 440 W Mitsuba 470 W Mitsuba 440 W Mitsuba 470 W
Spark plug NGK CR7E NGK CR7EB
Mitsuba
Magneto flywheel Mitsuba 235 W Mitsuba 235 W
235 W/330 W
Fuel supply Carburettor Indirect electronic injection (EFI)

„ Capacities

Engine oil 1.25 l SAE 10W40

Relay box oil 0.12 l SAE 80W90 life lubricated

3
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 SPECIAL IMPORTANT POINTS

SPECIAL IMPORTANT POINTS

„ Oil and fuel

This engine is designed to run on 95 or 98 unleaded fuel only.

Never run the machine with a petrol/oil mixture.

The fuel pipes must be changed if they show signs of wear, cracks, etc.

The clips are specific, they must always be changed each time they are removed
and replaced with new genuine parts clips.

Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames or
sparks. Work in a clear and well-ventilated area.

4
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 TIGHTENING TORQUE

TIGHTENING TORQUE

Cylinder head 1.8/2.3 m.daN

Cylinder casings 1 m.daN
Transmission cover 1 m.daN
RH casing cover 1 m.daN
Automatic tensioner 1 m.daN
Oil control valve 4 m.daN
Temperature sensor 1 m.daN
Starter motor 1 m.daN
Rotor 7 m.daN
Stator 1 m.daN
Engine speed sensor 0.7 m.daN
Drive pulley 7 m.daN
Driven pulley 7 m.daN
Spark plug 1 m.daN
Camshaft gear 2.3 m.daN

5
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 SPECIAL TOOLS

SPECIAL TOOLS

Casing
Casing Protective
opening
64706 extractor and 69098 end-piece 64706
plate +
opening tool large model
pin

750 +
64711
Shouldered
+
64710 centering 64706 69104 Pin nut
64712
tool
+
64754

Pin Ø12 Tie-wrap

64712 69104 750539
pitch 125 pliers

Engine
Engine Piston circlip
64765 mount 752000
mount pliers
adapter

68994
Flywheel
68570 752235 1/2 extension or
clamp
753977

Extensi
Torque
on 68994
wrench 1/2
68994 752235 752236 or
8 N.m to 3/8 adapter
Adapter 753977
54 N.m
752236

External Adjustable
69092 752237
circlips pliers pin wrench

6
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 SPECIAL TOOLS

Engine
mount
Crankshaft
753711 adapter 64765 754033
locking pin
Elyseo
Elystar

752235
Torque
extensi
wrench
on Camshaft
753977 30 N.m to 754034
752236 locking pin
150 N.m
adapte
r

Flywheel
754003 69098 754035 Valve lifter
puller

Clutch
46 mm pipe
754005 compression 754046 754040 754005
wrench
tool

Casing Timing
754006 opening 64706 754041 casing seal
plate drift

Mechanical Bearing
754007 755585
seal drift extractor tool

Engine
Water pump mount
754008 756717 64765
seal drift adapter
Jetforce

Water pump Fixed flange

754009 757035
pin drift locking tool

7
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 SPECIAL TOOLS

Water pump Water pump

757988 757989
bearing drift bearing drift

Crankcase
seal
757990
installation
buffer

8
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 DISASSEMBLY

DISASSEMBLY

„ Putting the engine on the stand.

753711
- Put the engine on the jig:
756717
P/N 753711 for engines FD1, FD2 and FD4.
P/N 756717 for engines FD5.
- Put the assembly on stand P/N 64765
clamped in the jaws of a vice.

64765
- Empty the oil from the engine

Note: Every time oil is changed, the filter

must be cleaned and the copper seal
changed.

- Tightening torque: 4 m.daN.

„ Removal of the primary transmission .

cover.
- Remove the 8 bolts that secure the cover.
- Remove the transmission cover and the
2 centring pillars.

- Tightening torque: 1 m.daN.

9
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 DISASSEMBLY

„ Removal of the drive pulley.

757035
- Remove the starter dog.
- Hold the fixed flange with tool P/N 757035.
- Remove the nut (1) and washer (2) from the
fixed flange
- Remove the fixed flange.

- Tightening torque: 7 m.daN.

2 1
- Remove the belt (3).
- Remove the drive pulley (4) with the guide 4 3
hub (5).

„ Removal of the driven pulley.

- Immobilize the clutch drum using the ajustable 68570
pin wrench P/N 752237 or the flywheel clamp
P/N 68570.
- Remove the nut. 1
- Remove the clutch drum and the clutch and
drive pulley assembly.

- Tightening torque: 7 m.daN.

10
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 DISASSEMBLY

„ Removal of the rocker cover.

- Remove the 5 fixing bolts.
- Remove the rocker cover.
- Remove the paper gasket.

- Tightening torque: 1 m.daN.

Note: The O-ring must be changed every

time it is removed.

Every time the rocker cover is removed and re-

installed, make sure the plug (1) is over the
gauge hole of the cylinder head.

„ Removal of the chain tensioner.

- Remove the screw and spring from the
tensioner (1). 1
- Remove the 2 mounting screws (2) from the
tensioner body.

11
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 DISASSEMBLY

- Remove the chain tensioner and slacken it by

pressing the ratchet tooth (A).
- Remove the paper gasket.

- Tightening torque: 1 m.daN.

„ Removal of the RH cover / ignition coil

and sensor.
- Remove the 8 bolts that secure the RH cover.
- Remove the cover.

- Tightening torque: 1 m.daN.

- Remove the paper gasket (1) and the

2 locating pins (2).

2
1

12
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 DISASSEMBLY

- Remove the engine speed sensor 2 fixing

bolts (3) and the stator assembly 3 fixing 3
bolts (4).
- Remove the stator and sensor assembly (3).

- Setting the engine speed sensor gap: 0.3 to

1.4 mm.
- Tightening torque: 1 m.daN.

Note: The oil flowing inside the cover and

the crankshaft stem shall lubricate
the conrod big end.. 4

The tighteness of the oil lubrication system

between the cover and the RH stem of the
crankshaft is provided by a seal
5
The seal is placed in the casing with its lip on the
casing side.
A circlip (5) holds the seal in its housing
The condition of the seal shall be checked every
time the cover is removed. And if necessary it
shall be replaced using the timing casing seal
drift P/N 754041.

„ Removal of the rotor.

- Immobilize the rotor (1) using the flywheel 68570 1
clamp P/N 68570
- Remove the nut.

13
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 DISASSEMBLY

- Fit protective cap P/N 69098 to the end of the .

crank assembly. 754003
- Tighten flywheel extractor P/N 754003 on the
rotor.
- Lock the flywheel extractor and turn the thrust
bolt until the rotor is released.
- Remove the rotor.

- Tightening torque: 7 m.daN.

69098

Note: When re-installing, make sure the

key (1) is properly positioned on the
crankshaft stem as shown in the 1
figure.

„ Removal of the cylinder head.

- Remove the spark plug.
- Rotate the engine by hand in the direction of
operation (clockwise) by means of the fixed
plate in order to bring the rocker pads over the
camshaft's cam lobes..

14
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 DISASSEMBLY

- Immobilize the camshaft gear (1) using the

adjustable pin wrench P/N 752237.
- Remove the camshaft gear bolt.
752237
- Remove the camshaft gear.
- Hang the timing chain.

- Remove the chain guide pad (2) (which is

fitted inside the cylinder head on the exhaust
side).
- Loosen the 2 washer screws (3).
- Gradually loosen in a crosswise order the 4
nuts which secure the cylinder head (4).
- Remove the 4 nuts and washers and the
2 washer screws. 3
4

- Remove the cylinder head, the metal seals (5)

and the 2 centring pillars (6).
6

15
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 DISASSEMBLY

„ Removal of the temperature sensor.

- The temperature sensor (1) is screwed into 1
the cylinder head.

- Tightening torque: 1 m.daN.

„ Removal of the thermostat.

- Remove the 2 bolts and the thermostat
valve (1). 2
- Remove the thermostat (2). 1
- Tightening torque: 1 m.daN.

Note: The drain bolt is located on the cover.

Tighteness of the bolt is provided by
a fiber seal.

„ Removal of the camshaft and/or rockers.

- Remove the 3 screws which secure the
stopper plate (1). 1
- Remove the stopper plate.
- Remove the camshaft (2).
- Tightening torque: 0,7 m.daN.

Note: The stopper plate has two functions.

to provide:
- proper positioning of the camshaft.
- flow of oil inside the rocker shafts.
2

16
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 DISASSEMBLY

- Remove the 2 rocker shafts (3).

- Remove the inlet (4) and exhaust (5) rockers.
4
5

When re-installing, the lubrication holes (A) of

the shafts shall be directed towards the stopper
plate.

„ Removal of the valves or valve stem

seals.
- Compress the spring of one of the valves
using the valve lifter P/N 754035.
- Remove the 2 half cones.
- Uncompress the spring and remove the tool.

754035

17
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 DISASSEMBLY

Remove:
- The upper cup (1). 1
- The spring (2) (when dismantling notice in
which direction it is so that you will replace it in
its initial position when reassembling). 2
- The lower washer (3).
- The valve (4).
- Remove the 2nd valve in the same way.
3

Note: When re-installing, lubricate the

2 half cones (5) so as to hold them in
the groove of the valve's stem.

Do not place the 2 half cones into the cup

forcefully with the tool when decom- 5
pressing the spring.

In case you remove the seal of a valve stem (6),

replace it with a new seal after removing all the
carbon residues which could remain inside the
cylinder head. 6
Important: When re-installing, the camshaft
bearings, the rocker shafts and the
contact between the rockers and the
valves shall well lubricated in order
to avoid any risk of seizure when
starting the engine (use a Molykote
type grease). Seals and valve stems
must be lubricated.

18
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 DISASSEMBLY

„ Removal of the cylinder.

- Remove the front bolt (1) of the cylinder
(located beside the oil pressure swich).
- Remove the cylinder.

- Remove the base gasket (2) and the

2 centring pillars (3).

2
„ Removal of the piston.
- Remove one of the circlips (1) with pliers
P/N 752000.
- Remove the gudgeon pin.
- Remove the piston.

752000

19
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 DISASSEMBLY

„ Removal of the oil pump. .

- Remove the 2 screws which secure the 1st
anti-splash plate (1).
- Remove the plate.

- Remove the 2 circlips (2) from the plastic

gears (3) which drive the water pump and oil 3
pump.

- Remove the plastic gears and the 2 pins (4).

- Remove the 2 screws which secure the 2nd 4
anti-splash plate (5).
- Remove the plate.

20
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 DISASSEMBLY

- Remove the 3 screws which secure the oil

pump (6).
- Remove the oil pump.

- Tightening torque: 1 m.daN.

Note: Before re-assembling, lubricate the

oil pmup by dipping it into a pan con-
taining clean motor oil.
6

21
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 DISASSEMBLY

„ Removal of the RH crankcase half.

- Remove the screw which secures (1) the 1
chain tensioner slipper (2).
- Remove the chain tensioner slipper.

- Tightening torque: 1 m.daN.

2

- Remove the timing chain and notice its

direction of rotation.

- Remove the 2 bolts that secure the starter

motor (3) 3
- Remove the starter motor.

- Tightening torque: 1 m.daN.

Note: Check the condition of the starter

motor O-ring.

- Remove the 8 bolts. One of which is located

on the LH casing..
- Remove the RH casing.
- Remove the 2 centring pillars and the paper
gasket.

Note: No tools are necessary to remove the

RH casing, as the bearing is secured
to the cranshaft and conrod ass'y.

- Tightening torque: 1 m.daN.

Check and if necessary clean the water pump

drain hole (A).

22
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 DISASSEMBLY

„ Removal of the oil discharge valve.

- The discharge valve (1) is screwed without
any seal in the casing.

- Tightening torque: 4 m.daN.

„ Removal of the water pump.

- Unscrew the turbine (1) from the drive
shaft (2) while immobilizing it using a 2 mm
diameter drift in (A).

- Remove the circlip (3) located on the bearing

side. 5 7 4 2
- Drive out the bearing (4) on the timing side by
pushing it out over the pump drive shaft.
- Drive out the mechnical joint (5) from the
turbine side.
- Drive out the seal 6 from the turbine side.
- Drive out the caged needle bearing (7) from
the turbine side.

1 6 3 A

All the components must be changed every time the pump is serviced..

23
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 DISASSEMBLY

„ Removal of the crankshaft.

- Remove the 2 screws which secure the water
inlet pipe (1).
- Remove the water inlet pipe and the O-ring.

- Tightening torque: 1 m.daN.

- Fit the protective cap P/N 69098 to the crank.

- Fit to casing with tool P/N 64706 fitted with
plate P/N 754006.
64706

69098 754006

- Fix the assembly to the casing using

4 bolts (2).
- Tighten the tool centre screw holding the
crank with one hand on the other side until it is
fully extracted.
- Removing the the cranshaft and conrod 2
assembly.

Note: When the casings are opened, if the

bearings stay on the crank, use tool
P/N 755585 to remove them. 2

24
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 DISASSEMBLY

„ Checking the crankshaft and conrod

assembly.
- Using a set of shims, check the big end side
play.
- The maximum side play on the conrod end
must not exceed: 7/10 mm.

The out-of-round values measured on the ends

of the crank should not exceed 5/100 mm and
must be measured:
- 30 mm from the transmission side end.
- 35 mm from the flywheel magneto end.

30 mm 35 mm

25
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 DISASSEMBLY

„ Removal of the secondary transmission

cover.

Note: Use a drip pan to catch the transfer

box oil when the cover is removed. 2
1
Filling and checking the transfer box oil level is
through the cap (1).

- Remove the transmission cover 5 fixing bolts.

- Remove the cover with the primary shaft (2).
- Tightening torque: 1 m.daN.

Note: The primary shaft can be drifted out

of the cover using a mallet.
„ Removal of the secondary transmission.
- Remove the 2 centring pillars and the paper 1 2
gasket (1).
- Remove the first friction washer (3) from the
intermediate shaft (4).
- Remove the secondary shaft (5).

Note: Make sure not to damage the gasket

on the wheel side when removing the
secondary shaft.

4 3 5
In case the gasket is damaged, oil will flow
through the casing's drain hole (A) located
between the gasket (on the wheel side) and the A
bearing.

26
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 DISASSEMBLY

- Remove the intermediate shaft and its second

friction washer (6) located behind it.
6

27
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 REFITTING SPECIFIC COMPONENTS

REFITTING SPECIFIC COMPONENTS

„ Installing the crankshaft LH bearing.

- The bearing is positioned into the casing by
757990
means of a press.
- Fit the seal into the casing using the
installation buffer P/N 757990.

„ Installing the water pump inside the RH

crankcase. 754009
- Fit the caged needle bearing (1) into the
casing on the turbine side using the pin drift
P/N 754009.

- Fit the seal (2) using the drift P/N 754008, the
seal's lips shall be directed towards the caged 754008
needle bearing..

28
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 REFITTING SPECIFIC COMPONENTS

- Install the bearing (3) on the drive shaft (4) by

pushing it by the inner cage using bearing drift
P/N 757988.
3

757988

4
- Fit the drive shaft and bearing assembly by
the outer cage using the bearing drift
P/N 757989.

757989

- Install the circlip (5) on the bearing side.

29
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 REFITTING SPECIFIC COMPONENTS

- Fit the mechanical joint (6) using the seal drift

P/N 754007. 754007
- Install the turbine.

Note: The new mechanical joint is delivered

with a blocking product coated on
the surface which is in contact with
the casing. Make sure not to damage
this product when handling the joint.

6
„ Assembly of the engine casings.
- Insert the crank assembly into the LH casing 64712
bearing.
- Tighten pin P/N 64712 at the end of the crank
assembly.

- Fit tool P/N 64706 fitted with plate P/N 754006

to the pin. 69104
- Centre the assembly to the casing with
4 bolts (1).
- Fit centring tool P/N 64710 to tool P/N 64706.
- Tighten pin nut P/N 69104 on pin P/N 64712 64710
in order to bring the crankshat assembly into 64706
contact with the bearing ensuring that the
crank is pointing towards the cylinder side.

Note: Hold the crank assembly by the RH

side using the rotor fitted on the key.
754006

30
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 REFITTING SPECIFIC COMPONENTS

- Fit the 2 centring pins (2) to the LH casing and

a new paper gasket (3) do not use oil or
grease.
2

2
- Place the RH casing over the LH casing
assembly.

Note: No tools are necessary for assem-

bling the casings, which shall be car-
ried out without effort.

- Fit and tighten the 8 fixing bolts .

- Tightening torque: 1 m.daN.

- Check the crank assembly turns freely in the

casings.
- Trim the casing gasket in (A).
- Lightly grease the crank assembly and
bearings with 4 stroke oil.
A

- Place the inlet pipe and the O-ring (check the

condition of the O-ring and if necessary
change it)..

- Tightening torque: 1 m.daN.

31
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 REFITTING SPECIFIC COMPONENTS

„ Installing the piston rings on the piston.

Proceed in the following order in order to install
the oil control rings. 4
- Install the spring (1) (no special direction).
- Install the 2 piston rings (2) on each side of
the spring by offsetting the gap of each ring
3
(no special direction).
- Install the compression ring (3) by placing 2
the"TOP" mark upwards.
- Install the top compression ring (4) by placing
the "0" mark upwards. 1

„ Fitting the piston.

- Install the piston with the arrow engraved on
the piston crown, on the timing side.

Note: Lubricate the piston pin.

Note: The circlips must be changed every

time they are removed.
1
The circlip gaps (1) must face upwards or
downwards, but under no circumstances to the
side.

32
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 REFITTING SPECIFIC COMPONENTS

„ Fitting the cylinder

- Install the cylinder base gasket and the 1
2 guiding pillars on the crankcase.
- Position the piston ring gap as follows.

0°
12
1. Top compression ring gap.

90°
2. Compression ring gap.
3. Upper oil control ring gap. 2
4. Lower oil control ring gap.

°
90
4
3
Note: Lubricate the cylinder.
2
- Fit the timing belt through the cylinder timing
well.
- Compress the piston rings and fit them
manually one after the other into the cylinder
barrel.
- Fit the cylinder front screw (beside the oil
temperature switch).
- Install the the chain tensioner slipper (2).

Note: The cylinder skirt is chamfered in

order to fit the piston rings easily.

„ Fitting the cylinder head.

- Fit the 2 guiding pillars (1) and the metal 1
gasket (2) on the cylinder.
- Fit the timing chain through the cylinder head
timing well.

2 1

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 REFITTING SPECIFIC COMPONENTS

- Install the cylinder head.

- Install the chain guiding slipper on the
crankcase pin (A) and the housing (B) in the
crankcase on the exhaust port side.

Method for tightening the cylinder head.

Standard nut (A). A
This is carried out in two steps:
• 1st step:
- Fit the 4 washers.
- Tighten the 4 nuts (1) and the 2 washer
screws (2) slightly.
- Pre-tighten the 4 nuts in a crosswise order to
18 Nm and the 2 washer screws to 8 Nm.
• 2nd step:
- Torque the 4 nuts in a crosswise order to
23 Nm and the 2 washer screws to 10 Nm.
B
Collar nut (B).
This operation is carried out in several steps:
- Slightly lubricate the studs.
- Fit the 4 washers.
- Tighten the 4 nuts (1) and the 2 washer
screws (2) slightly.
- Torque the nuts to 6 Nm.
2 1
- Pre-tighten the 4 nuts in a crosswise order to
15 Nm and the 2 washer screws to 8 Nm.
- Loosen each nut by 90° and re-tighten them to
28 Nm in a crosswise order.
- Tighten the 2 washer screws to 8 Nm.
-

You must set the timing every time you remove the cylinder head when servicing.

34
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 REFITTING SPECIFIC COMPONENTS

„ Setting the timing.

Every time you set the timing you must: 754033
- Empty the oil from the engine.
- Remove the RH cover.
- Remove the flywheel magneto rotor.
- Remove the automatic tensioner.

- Fit the locking pin P/N 754033 in the

crankcase gauge hole.
- Rotate the crankshaft until the pin enters the
crankshaft gauging hole.

- Install the camshaft gear (1) on the camshaft.

- Immobilize the camshaft gear using the 1
adjustable pin wrench P/N 752237.
- Tighten the camshaft gear screw.

- Remove the cylinder head gauging hole plug.

- Insert the pin P/N 754034 into the cylinder
head gauging hole. 754034
- Rotate the camshaft until the pin enters the
camshaft gauging hole.
- Remove the camshaft gear.

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 REFITTING SPECIFIC COMPONENTS

- Place the camshaft gear (1) in the timing

chain so that you can immobilize it using the
adjustable pin wrench P/N 752237. 1
- Fit the camshaft gear screw but do not tighten
it.

- Fit the chain tensioner seal (respect the

position of installation).
- Install the chain tensioner and the
2 attachment screws.
- Install the spring and its screw.

- Tightening torque: 1 m. daN.

- Immobilize the camshaft gear using the

adjustable pin wrench P/N 752237.
- The lower strand of the chain shall be kept
taut.
- Tighten the camshaft gear screw.

- Tightening torque: 2.3 m.daN.

Checking the timing:
- Remove the 2 timing pins.
- Rotate the engine twice: 2 revolutions in the engine's operating direction (clockwise).
- Fit once again the pins in order to make sure timing is set correctly.
- If the pins do not enter reset the timing.
- Fit the plug over the cylinder head gauging hole.

36
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 REFITTING SPECIFIC COMPONENTS

„ Installing the valve clearance.

- Rotate the engine manually either by means
of the pulley or the rotor (as appplicable) in the
direction of operation (clockwise) so as to
bring the rocker pads over the cam lobes.

- Loosen the lock nut of the rocker adjustment

screw.
- By means of feeler gauges, adjust the
clearance of every valve by acting on the
rocker set screw.

Clearances:
• 10/100 at the intake.
• 25/100 at the exhaust.

- Immobilize the rocker set screw.

- Tighten the nock nut.

„ Checking the valve clearance.

- At the intake a 15/100 feeler gauge shouldn't go.
- At the exhaust a 30/100 feeler gauge shouldn't go
On the contrary, if the fealer gauge goes, reset the clearances.

37
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 REFITTING SPECIFIC COMPONENTS

„ Refitting the rocker cover.

Important:
Make sure you fit the plug (1) over the cylinder 1
head gauging hole.
- Install a new paper gasket.
- Install the rocker cover and its 5 scews.

- Tightening torque: 1 m.daN.

If you forget to fit the plug (1) the oil pressure will be low and some components could seize.

38
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 MISCELLANEOUS OPERATIONS

MISCELLANEOUS OPERATIONS

„ Removal of the oil filter.

- Remove the 2 screws which secure the oil 2 1
filter cover (1).
- Remove the cover and the O-ring (2) (check
the condition of the O-ring and change it if
necessary).
- Remove the oil filter (3).

Note: The oil filter has no installing direc-

tion.

- Tightening torque: 1 m.daN. 3

„ Removal of the water inlet pipe.

- Remove the 2 screws which secure the water
inlet pipe (1).
- Remove the water inlet pipe and the O-ring (2) 2
(check the condition of the O-ring and change
it if necessary).

- Tightening torque: 1 m.daN.

39
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 MISCELLANEOUS OPERATIONS

„ Fitting the drive pulley assembly.

- Fit the drive pulley with its guide hub (1) onto
the crank assembly. 4 3 1
- Fit the belt (2) to the guide hub.
- Fit the fixed flange (3) to the crank assembly
checking it is properly positioned on the crank
assembly splines.
- Fit the washer (4) and the nut and hand
tighten.
- Hold the fixed flange with tool P/N 757035.
- Tighten the nut.

- Tightening torque: 7 m.daN.

2

It is forbidden to use a power driver, this may upset the crank position.

Precautions when refitting the drive pulley:

Drive pulley components shall neither be suppressed nor have their size reduced.
Any modifications may cause the nut to tighten against the crankshaft splines instead of the
fixed flange and damage the crankshaft splines.

„ Changing the drive pulley bearings.

- Remove the 8 screws which secure the 757035
primary transmission cover.
- Remove the transmission cover.
- Lock the fixed flange (1) with tool P/N 757035.
- Remove the nut (2) of the fixed flange.
- Remove the fixed flange.
- Remove the belt.
- Remove the guide hub and the drive pulley.

1 2

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 MISCELLANEOUS OPERATIONS

- Remove the holder (3) and its (4) plastic

guides.
- Remove the moving flange (6) 6 bearings (5).
6 4
Note: The bearings must be changed if they
show major signs of wear.

Re-assembly:
Proceed in reverse order to disassembly and do
not grease the bearings.
Grease the moving flange bore lightly (high
temperature grease).

5 3
„ Removal of the clutch lining assembly.
- Remove the transmission cover 8 fixing bolts.
- Removal of the primary transmission cover.
- Lock the clutch drum with the pin wrench
P/N 752237.
- Remove the nut.
- Clamp the 2 strands of the belt to lower it
between the flanges.
- Remove the clutch drum, the clutch drive
pulley and driven pulley assembly and belt.

- Compress the clutch drive pulley and driven

pulley assembly with the tool P/N 754005 754005 754040
clamped in the jaws of a vice.
- Remove nut (1) using spanner P/N 754040
- Slacken tool P/N 754005.

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 MISCELLANEOUS OPERATIONS

- Remove the clutch linings (2), the upper

centring sleeve (3), the spring (4), and the 2 3 4 5
lower centring sleeve (5).
- Remove the 3 pins (6) from the variable
speed drive seat
- Separate the fixed (7) and rotating (8) flanges.

6 7 8
„ Refitting the clutch lining assembly.
- After checking the 2 lip seals (1) and the 2 O- 1
rings (2) of the rotating flange (7) are in good
condition, grease the governor seat 3 pins (6)
(high temperature grease) and assemble the
parts in reverse order to removal.

- Compress the clutch drive pulley and driven

pulley assembly with the tool P/N 754005.
- Tighten the nut.
- Tightening torque: 4.5 m.daN.
2 7

Before fitting the clutch drive pulley and driven pulley to the input shaft, fit the belt into the pulley
bottom by opening the flanges by hand.

- Fit the clutch drive pulley and driven pulley assembly.

- Fit the clutch cover.
- Fit and tighten the nut.
- Tightening torque: 7 m.daN.

- Install the transmission cover.

- Fit and tighten the cover 8 fixing bolts.
- Tightening torque: 1 m.daN.

42
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 RECOMMENDS

P/N 757904

In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress,
modify, or add any reference mentioned.
DC/PS/APV Printed in the E.U. 07/2004 (non contractual pictures)

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